Hydraulic Chassis Lift System Operating and Maintenance Manual

Transcription

1 Hydraulic Chassis Lift System Operating and Maintenance Manual Demountable Concepts, Inc. 200 Acorn Road LOCAL (856) WEB demount.com Glassboro, NJ FAX (856) Version 1.0 February 19, 2018 Demountable Concepts, Inc.

2 TABLE OF CONTENTS Section 1 System Components Page 3 Section 2 Demounting a Body Page 4 Section 3 Mounting a Body Page 8 Section 4 90-Day Maintenance Check List Page 12 Section 5 Troubleshooting Guide Page 14 Section 6 Bleeding Instructions - New Installation Page 18 Section 7 Bleeding Instructions - Existing System Page 21 Section 8 Check and Set Hydraulic Pressure Page 24 Section 9 Greasing Diagram Page 25 Section 10 Electrical Diagrams Page 26 Section 11 4-Way Light Plug Wiring Diagram Page 28 Section 12 Pump Units Page 29 Section 13 Can vs. Powerseal Diagram Page 31 Section 14 Hook Measurement Drawing Page 32 Section 15 Parts List Page 33 Section 16 Contact Information for Service and Parts Page 36 2

3 SECTION 1 System Components Chassis Lift Mounted to Straight Truck Chassis Rear facing flood lights on left and right side of cab Front hydraulic lifting cylinder Wing plates Dash mounted lifter power cut-off switch Lifter controller mounted inside weather-proof box; locking handle Locking hooks secure demountable bodies to the truck s chassis Rear hydraulic lifting cylinder Lifting frame 12-volt hydraulic pump and motor with pressure relief valve and 150 amp circuit breaker Base Frame Built into Demountable Truck Body Body long rails Body locking bars Scrubber plates located at front and rear of long rails Retractable legs slide in and out of housing located under floor of body Light plug receptacle Leg locked into retracted position during transport 3

4 SECTION 2 Demounting a Body Preparing to Demount a Body 1. Put the truck in neutral and set the parking brake. 2. Switch dash mounted lifter power cut-off switch to on. 3. IMPORTANT: For lift gate-equipped vehicles, unlock and lower the lift gate to clear body long rails. See Figure 1. Figure 1. Unlocking the Demountable Body Body long rails Lift gate 1. Remove lock key. 2. Push yellow safety pin handle in to unlock pin. 3. Push the large black locking handle down. The cab-mounted safety buzzer/light will activate. This indicator will continue until the body is properly locked onto the truck chassis. Lifting a Truck Body 1. Disconnect the light plug from the body. 2. Insert the plug into the light plug holder. 3. Lift the body by pressing the UP button until the desired height is obtained. 4

5 SECTION 2 Demounting a Body Lifting a Truck Body (Cont'd.) 4. Raise the body to a height that when the retractable legs are set and the lifting frame is lowered, it will stand at your desired loading height. There must be approximately 2" of clearance between the lifting frame and the standing body. Air suspension can be dropped to achieve lower dock heights.! WARNING: Never drive with the body elevated or unlocked. 5

6 SECTION 2 Demounting a Body Setting the Retractable Legs When setting the legs always wear gloves for hand protection.! WARNING: NEVER put fingers into holes in legs. 1. Unlock and remove the chained pin from the foot of leg under the body side rail. Arm Brace 2. Grab footpad ring with fingers wrapped around the underside footpad and pull partially out. 3. Remove pin and insert into the correct hole. 4. Pull leg the rest of the way out and lower to vertical position. 5. Push leg assembly into housing until arm brace touches the body side rail. 6. Put chained pin through upper brace and leg. Tab Tab in proper position for securing pins 7. Check that all pins are secured and locked into the proper position with tab perpendicular to pin. 8. Check all people clear. 6

7 SECTION 2 Demounting a Body Lowering the Lifting Frame 1. With all four legs set and pinned securely, the lifting frame can be lowered.! 2. Push the DOWN button on the lifter controller to lower the lifting frame back to the truck chassis. WARNING: Check to be sure that all people are clear of truck and body before lowering lifting frame and pulling out from body. 3. Lower the lifting frame until a higher pitched sound is heard from the hydraulic pump. This indicates that the lifting frame is fully lowered. Pulling Truck Out From a Standing Body 1. Release parking brake. 2. Slowly drive truck straight forward. 3. Be sure to drive straight out at least the length of the truck body. If the truck chassis is equipped with a lift gate, be sure the gate clears the standing body. This requires lowering the lift gate to clear body before pulling forward. 7

8 SECTION 3 Mounting a Body Backing Under the Body The cab-mounted buzzer/light will sound when the locking system is unlocked and will continue until the body is properly locked onto the truck chassis. 1. The system locking handle must be in the lowered, unlocked position. 2. Back under the truck body by lining up the lifting frame to be directly between the two truck body long rails. 3. Back under slowly until the front mast behind the cab contacts the truck body s front scrubber plates just above the guide rails. Do not hit the body too hard. IMPORTANT: For lift gate equipped vehicles, unlock and lower lift gate to clear body long rails Lift gate Body long rails Scrubber plates are located at the front and rear of the body long rails 8

9 SECTION 3 Mounting a Body Preparing to Mount a Demountable Body 1. Put the truck in neutral and set the parking brake.! WARNING: Never drive with the body elevated or unlocked Lifting the Freestanding Body Figure Push the UP power button to raise the lifting frame. This will self-center the lifting frame between the body guide rails. 2. Lift the body until all legs clear the ground. See Figure 1. 1" to 2" of clearance between the bottom of legs and the ground 9

10 SECTION 3 Mounting a Body Storing Legs : When storing the legs ALWAYS wear gloves for hand protection.! WARNING: NEVER put fingers into holes in legs. 1. Store all legs from passenger side front to driver side front. Remove chained pin from stabilizer brace. 2. Lift entire leg to horizontal position and slide partially into the leg housing. 3. Remove lower leg pin, slide in inner leg. Insert pin through inner and outer side of leg at last hole. 4. Push leg completely into housing, keeping fingers clear. 5. Insert pin through leg retainers on body and loop on foot pad. 6. Flip lock on pin into place. Check to be sure all legs are locked into place. Tab Tab in proper position for securing pins Check to be sure that all people are clear of truck and body before storing the legs and lowering the body.! WARNING: Never drive with the body elevated or unlocked. 10

11 SECTION 3 Mounting a Body Lowering the Truck Body 1. With all four legs locked into the housing compartments, the body can now be lowered. 2. Push the DOWN button to lower the lifting frame onto the truck chassis. 3. Lower the lifting frame until a higher-pitched sound is heard. This indicates that the lifting frame is fully lowered. Locking the Truck Body 1. Lift the large black locking handle up. 2. The spring-loaded pin should go into place. 3. Insert the locking key into its hole. Cab safety buzzer/light will stop buzzing when the body is properly locked to the truck chassis. Double-check to be sure locking hooks are in proper position, securely over body lock bars 4. For lift gate equipped vehicles, raise lift gate and secure it in the locked position. 5. Switch dash mounted lifter power cut-off switch to "off". The unit is now ready to be driven. 11

12 SECTION 4 90-Day Maintenance Check List Lifter maintenance to be done with no bodies attached (Chassis only). This checklist is in addition to standard chassis maintenance procedures. A. Run System and Inspect Run the lifting frame up and down to insure smooth operation Inspect all nuts, bolts and cotter pins for proper tightness Inspect lifting frame and locking devices for abnormalities Inspect front and rear masts; clean any accumulated debris from bottom of rear mast Inspect all hydraulic fittings and fluid lines for leaks Check that the oil is clean and that the reservoir is filled within two inches of the top Inspect the hydraulic cylinder shafts for dirt, gum or varnish Wipe off any accumulation with kerosene and then with light grade motor oil Check system pressure Check for side play in lifter rear cylinder B. Grease Grease all locking shafts Grease locking lever Grease front and rear masts with lithium grease spray C. Locking Hooks Check measurements of front hooks Check measurements of rear hooks Adjust front and rear hooks if required Check body stops Check warning system Check that locking lever is in good working order 12

13 SECTION 4 90-Day Maintenance Check List D. Electrical Check all truck lights Check light plug Check battery terminals for corrosion Check circuit breaker terminals for corrosion Check solenoid terminals for corrosion Check ground connection Check voltage to system E. Clean System Remove body from truck Power wash truck chassis Power wash rear mast bottom Oil Recommendations Use Automatic Transmission Fluid, Dextron III or equivalent hydraulic oil. 13

14 SECTION 5 Troubleshooting Problem Possible Cause Correction Motor does not start. Dash-mounted cut-off switch is off. Turn switch on. Chassis Lift power fuse is blown. Circuit breaker is tripped. Pump motor solenoid. Bad ground. Dead battery. Battery cables. Low voltage controller security code has not been entered. (If equipped) Low voltage controller has automatically shut off after 20 minutes of non-use. (If equipped) Low voltage controller is defective. (If equipped) Switch on A frame is defective. Motor is defective. Replace the 15 amp in line fuse box. Reset or replace the circuit breaker located in the Chassis Lift pump box. Check voltage on motor side of solenoid while pushing up or down. If there is no voltage, replace the solenoid. Be sure the motor is properly grounded. Charge or replace the battery. Check that all connections are clean and tight. Inspect for breaks and replace if necessary. Enter code A, B, A, B, into the controller. Enter code A, B, A, B, into the controller. Enter code A, B, A, B into controller. If motor still does not start replace controller. Check for line voltage in junction box at terminal 1. Replace switch. If all above is checked, and the motor is getting power at the post, replace the motor. 14

15 SECTION 5 Troubleshooting Problem Possible Cause Correction Motor starts, but lifting frame will not raise/lower. Low line voltage. Control valve not shifting. Check voltage at terminals 3 and 4, charge battery, check and clean all connections. Clogged pressure relief valve. Defective pressure relief valve. Defective control valve. Clear pressure relief valve and reset pressure per instructions. If above process doesn t work, replace the valve. Replace valve. Chassis lift doesn t lower completely Improper amount of Hydraulic Oil in Closed section of Hydraulic System (Units built after 2004) Check hydraulic reservoir is full, press and hold the down button for 10 seconds to auto bleed the system, repeat if necessary after 30 seconds. If problem still exists increase pressure on the pressure control valve under pressure gauge. First loosen the lock nut, then turn the Allen head screw clockwise in until pressure reaches 1500 lbs, then press and hold the down button until lifter is completely lowered. (Reference page 24) Lifting frame FRONT goes down, but BACK will not go down all of the way. Ice or debris on, or between truck chassis and lifter. (Units built before 2004) Dirt and/or rocks in rear mast. (Units built before 2004) Not enough oil in closed section of hydraulic system. (Units built before 2004) Raise lifting frame and clean off debris. Clean or power wash rear mast and bottom section. Open rear bleeder plug and push down button (See Bleeding Instructions - Pg. 21). Be sure you have a minimum of 1500 PSI. 15

16 SECTION 5 Troubleshooting Problem Possible Cause Correction Lifting frame BACK goes down but FRONT will not go down all of the way. Lifting frame BACK goes up but the FRONT does not. Lifting frame moves side to side. Ice or debris on or between truck chassis and lifter. (Units built before 2004) Excess oil in closed section. (Units built before 2004) Defective pressure relief valve in front of system. (Units built before 2004) Bad rear cylinder piston seals. (Units built before 2004) Not enough oil in closed section of hydraulic system. (Units built before 2004) Too much space between front and/or rear masts - plastic slide blocks and channel. Raise lifting frame and clean off debris. Open front bleeder plug and push the down button on the controller (See Bleeding Instructions - Pg. 21). Be sure there is a minimum of 1500 PSI. Replace pressure relief valve at front cylinder. Replace rear cylinder piston seals or cylinder. Bleed rear cylinder and be sure you have 1500 PSI. (Reference page 24) Raise lifting frame half way and place shims behind plastic slide blocks until tight. Call factory Front or rear mast is bent. Call factory Body will not lock on easily. Body is not forward enough. Back the truck up until the front mast on cab contacts the front scrubber plates on the front of the body. Body is not forward enough. Ice or debris on or between truck chassis and lifter. Check and remove any ice, snow, debris or obstruction that may be built up in front of body. Raise lifting frame and clean off debris. 16

17 SECTION 5 Troubleshooting Problem Possible Cause Correction Excess oil in closed section. Bleed front cylinder and be sure there is a minimum 1500 PSI. (Reference page 24) Body goes out of balance regularly. Oil overflows from the reservoir when lowering body. Oil overflows from the reservoir when lowering body especially with heavily loaded body. Body slams or moves while in transit. System needs to be bled. Bad rear cylinder piston seals. Defective pressure relief valve Down flow valve is not set properly. Down flow valve is not set properly. Hooks are not adjusted properly. Bleed system per instructions. Install self-bleeding kit (Units before January 2004). Replace rear cylinder piston seals or cylinder. Replace front pressure relief valves. Set flow valve with a full body until it lowers at same rate as it goes up, or reads 350 PSI pressure A when lowering. B Set flow valve without a body to read 350 PSI pressure when lowering. Set down flow pressure to 350 PSI when lowering, without a body installed. Optional: With full and loaded body, pressure should be slightly positive when lowering. Check and adjust hooks. Call for instructions. Body lights do not work. Light plug wiring. Check that all wire connections are tight and wired to the correct pin. Light plug is dirty. Blown fuse Use a light plug wire brush and clean the light plug and socket. Locate and replace fuse in truck cab or pump box for body lights. 17

18 SECTION 6 Bleeding Instructions for New Installation or Replacement Pump Read All Instructions Before Starting Two people are required to perform this procedure. Always wear safety glasses. Figure 1 Flow valve location inside pump box 1. The lifting frame must be fully lowered, flush on the chassis and unlocked. 2. Open the flow valve inside the pump box. The valve is located on the left, rear inside of the pump box. Loosen lock nut and turn valve counter-clockwise to open. (Figure 1) 3. Use a small funnel or a pump to fill up the plastic reservoir. Use Automatic Transmission Fluid, Dextron III or equivalent. 4. Mounted to the REAR cylinder is a 22" long steel pipe. Disconnect the 1/2" hose at the 90 degree swivel at the top of this pipe. (Figure 2) Have a helper hold this hose in a bucket. Always wear safety glasses. Figure 2 18

19 SECTION 6 Bleeding Instructions for New Installation or Replacement Pump 5. Go to the control box and push the UP button. Watch the plastic reservoir. DO NOT RUN THE OIL LEVEL LOW (less than 2" from bottom). Stop periodically and add additional oil. Air will come out of the hose first, then oil. Make sure you have a steady flow of clear oil. Do not let the reservoir run out of oil during this process. If, when pushing the UP button, no oil comes out of the hose - STOP. Go to the junction box and double check that the green and red wires are not crossed. If the wiring is correct, check that the two hoses from the pump are not crossed. 6. Stop when a steady flow of oil comes out of the hose. Re-connect the hose to the swivel on the steel pipe. 7. Have helper stand clear. Check for any clamps holding the lifting frame to the vehicle. Fully raise the lifting frame by pressing the UP button. DO NOT RUN THE OIL LEVEL LOW (less than 2" from bottom). Stop periodically and add additional oil. When the lifting frame is approximately 2" from its maximum height, a gush of air may return to the plastic reservoir. Be sure to loosely hold a clean rag over the fill port of the plastic tank. The pump will decrease the truck battery power. Run the truck to maintain proper power. 8. Lower lifting frame all the way. DO NOT RUN THE OIL LEVEL LOW (less than 2" from bottom). Stop periodically and add additional oil. When the lifting frame is fully lowered and the relief valve opens, check pressure on the pressure gauge. Pressure should be 1500 PSI. If pressure is not 1500 PSI, loosen lock nut and turn the Allen screw on the pressure relief valve clockwise until it reads 1500 PSI. If pressure does not increase, unscrew the Allen screw all the way and push DOWN for 10 seconds to flush out the relief valve. Turn Allen screw in until gauge reads 1500 PSI. Tighten lock nut. 19

20 SECTION 6 Bleeding Instructions for New Installation or Replacement Pump 9. Fully raise the lifting frame by pushing the UP button on the lifter controller. 10. IMPORTANT: Be sure to return to the pump box to set the flow valve. The valve must be set so that the lifting frame lowers SLOWER than it raises or oil will overflow. The pressure gauge should read approximately 350 PSI without a body on the chassis. Tighten the lock nut. 11. When the lifting frame is lowered, be sure it is sitting on top of the front mounts. When fully lowered, any space here will indicate air is trapped in the top of the front cylinder. If you feel the need to re-bleed the system because the unit will not fully lower onto the chassis follow our standard bleeding instructions. 20

21 SECTION 7 Bleeding Instructions for an Existing System Read All Instructions Before Starting 1. The lifting frame must be fully lowered and unlocked. Do not bleed the system with a body on the vehicle. 2. Use a small funnel or pump to fill up the plastic reservoir with Automatic Transmission Fluid, Dextron III, or equivalent. 3. Go to the right side of the FRONT hydraulic lifting cylinder (at the top) and open the bleeder port. There may still be some pressure in the cylinder. Always wear safety glasses. Bleeder Port Two people are required to perform this procedure. 4. After opening the bleeder port, have a helper hold a container at the bleeder plug opening to catch the oil. Holding a short flexible hose over the bleeder plug will make capturing the oil much easier and cleaner. 5. Go to the control box and push the DOWN button. Watch the plastic reservoir. DO NOT RUN THE OIL LEVEL LOW (less than 2" from bottom). Stop periodically and add additional oil. Air will come out of the bleeder port opening first, then oil. Make sure you have a steady flow of clear oil. If no oil comes out, check the pressure gauge. If it reads less then 1500 PSI, then set the pressure (See Check and Set the Hydraulic Pressure - pg 24). Try to bleed 2 quarts of oil. Do not let the reservoir run out of oil during this process. 6. Stop the pump. 7. Close bleeder plug snug. DO NOT OVER TIGHTEN. 21

22 SECTION 7 Bleeding Instructions for an Existing System 8. Go to the left side of the REAR hydraulic lifting cylinder (at the top) and open the port. There may be some oil or air pressure in the cylinder. 9. After opening the bleeder port, have a helper hold a container at the bleeder port opening to catch the oil. Holding a short flexible hose over the bleeder plug will make capturing the oil much easier and cleaner. 10. Go to the control box and push the DOWN button. Watch the plastic reservoir. DO NOT RUN THE OIL LEVEL LOW (less than 2" from bottom). Stop periodically and add additional oil. Air may come out from the bleeder port opening first, then oil. Make sure you have a steady flow of clear oil. Do not let the reservoir run out of oil during this process. Stop the Pump. Rear Bleeder Port Location 11. Have helper stand clear. Fully raise the lifting frame by pushing the UP button. The pump will decrease the truck s battery power. Run the truck during this procedure to maintain proper power. Do not lower the system until all air has settled in the plastic tank. Lowering the system with air in the oil may require another bleeding procedure! 12. IMPORTANT: Be sure the flow valve is set correctly. The valve must be set so that the lifting frame lowers SLOWER than it raises or oil will overflow. The pressure gauge should read around 350 PSI when lowering without a body. Tighten lock nut (Figure 1). (Figure 1) 22

23 SECTION 7 Bleeding Instructions for an Existing System 13. When the lifting frame is lowered, be sure it is sitting on top of the front mounts. When fully lowered, any air space here will indicate air is trapped in the top of the front cylinder. This procedure may have to be done two or three times. If you think you have an air-bleeding problem PLEASE carefully check if air or frothy oil comes out of the front bleeder port during initial bleeding. If you have repeated problems and only oil comes out, please call Demountable Concepts, Inc. at If you are installing a new Chassis Lift, a new pump, and a new cylinder or have lost a major amount of oil, please call Demountable Concepts, Inc. at for a different set of bleeding instructions. 23

24 SECTION 8 Check and Set Hydraulic Pressure Read All Instructions Before Starting 1. The lifting frame must be fully lowered and unlocked. 2. Locate pressure gauge mounted to the side of the hydraulic unit (See Figure 1). 3. Push the DOWN button on the lifter controller and note the pressure. 4. Pressure should be 1500 PSI. To remove pressure from the line after testing, push up for 1/2 second. Gauge should show 0 PSI. 5. To increase pressure, first loosen the lock nut then turn the Allen head screw IN on the front of the pressure relief valve on the hydraulic pump (See figure 2). If pressure does not increase, the relief valve may be clogged. 6. To unclog the pressure relief valve, unscrew the Allen head screw as far as possible. Run the pump to remove debris. Turn screw IN to re-set the pressure to 1500 PSI. If pressure does not increase, you may have to replace the pressure relief valve. Part number for this valve is DCI Please call Demountable Concepts, Inc., at , if you have any questions. Two people may be required to perform this procedure. Figure 1 Figure 2 24

25 SECTION 9 Greasing Diagram 25

26 SECTION 10 Electrical Diagram 26

27 SECTION 10 Electrical Diagram GOLD LEAD FIREWALL GOLD LEAD A 2.9A BACK OF PUMP BOX BLACK FUSE BLOCK Black RED 10GA FLOOD RED w/ Loom Covering YELLOW RED GREEN CONTROL RED (DOWN) WEATHER TITE FUSE HOLDER WAYTEK RED (DOWN) BLACK (HOT) GREEN (GND) RED (DOWN) GREEN (UP) WHITE (UNUSED) SIDE OF PUMP BOX CONTROL BOX WIRING: WHITE #2 (UNUSED) GREEN #3 (UP) RED #4 (DOWN) BLACK #6 (HOT) 7 27

28 SECTION 11 4-Way Light Plug Wiring Diagram 28

29 SECTION 12 Pump Unit M WHITE WIRE (ATTACH TO SOLENOID START POST) CONNECT THRU "B" COIL STRAIN RELIEF 22 WIRE TO UNIT WHITE WIRE,CONNECT THRU "A" COIL STRAIN RELIEF 24 M REV: - "A" COIL (GREEN WIRE) "B" COIL (RED WIRE) RED WIRE (ATTACH TO "B" COIL) GREEN WIRE (ATTACH TO "A" COIL) WHITE WIRE (ATTACH TO WHITE WIRE FROM MOTOR START SOLENOID) ITEM NO QTY. PART NO DESCRIPTION BASE ASSY,M3598,MOD,STD MTR/MT P ASSY,QM,MDLR,DC,BRG RSV,1/2" SCREW,SHC,1/4-20 X 3.25,BLK OX NIPPLE,1/2 NPT X 2,SCH FITTING,ELBOW,90 DEG,PIPE,BLCK FILTER,SUCTION,1/2" NIPPLE,1/4 X ELBOW,90 DEG 1/4NPT X 1/4 NPT TUBE,RTN,STR,1/4 NPT,PVC O-RING,0.63 X 0.75 X MANIFOLD,D03,1 STA,VLV,M SCREW,SHC,1/4-20 X 1.50,BLK OX Y VALVE,ELEC,12VDC,4W/3P,D03,CC PLUG,SAE O-RING,9/16-18,HEX,SO S MOTOR,DC,12V,4.5",1 TERM SWITCH,SOL,12VDC,3-POST,M-SER STRAP,MOTOR-SOLENOID CONNECT SCREW,PAN HD,TORX,10-32 X 5/ RESV,PLASTIC,5.5X6.5X CLAMP,HOSE,WORM GEAR,RSV,M-SER PLUG,RESEV,BREATHER-FILLER CORD ASSY,HRNSS,WHT WIRE,15"LG CORD ASSY,HRNSS,3 WIRE,24"LG FITTING,STRN.REL.WP 3/8" CORD STRAP,CONNECT PLATE,D03 VLV TERMINAL,CLS END CONNECT,SMALL 23 WIRE TO UNIT SHIP LOOSE (PLASTIC PLUG) 19 "A" OUTLET PORT 9/16-18 SAE #6 (STEEL PLUG REF) "B" OUTLET PORT 9/16-18 SAE #6 (STEEL PLUG REF) "B" OUTLET PORT 9/16-18 SAE #6 (STEEL PLUG REF) C1 C1 "A" OUTLET PORT 9/16-18 SAE #6 (STEEL PLUG REF) SEE NOTE # /8" /4" 2 MOUNTING HOLES 3/8-16 UNC-2B 19 3/4" DRAIN HOLE REF /16" 1 BASE /8" 3 6 VIEW SHOWN WITHOUT RESERVOIR 9 RELIEF VALVE (01316-FILTER REF RETAINING SPRING REF) - - NOTES: 1. CLAMP MUST BE INSTALLED AT THIS LOCATION. THIS PRINT IS THE PROPERTY OF MONARCH HYDRAULICS INC., AND IS NOT TO BE USED DIRECTLY OR INDIRECTLY IN ANY WAY DETRIMENTAL TO OUR INTEREST NON-SPECIFIED TOLERANCES:.XX ±.010.XXX ±.005 FRACT. ± 1/32 ANGLES ± 1/2 BREAK EDGES REMOVE BURRS [MILLIMETER] INCH REV CUSTOMER: N/A DESCRIPTION DESCRIPTION: PUMP UNIT, M , HORZ MT, 12 VDC MONARCH HYDRAULICS INC. GRAND RAPIDS, MI USA DO NOT SCALE DATE: 3/19/2009 DRAWN BY: PDA SIZE: D REV BY: - REV DATE: EWR: DRAWING #: REV: SHEET 1OF: 1 M

30 SECTION 12 Pump Unit M THIS DRAWING WAS ACCESSED ON 9/3/2015 AT 2:45:28 PM "A" M OUTLET PORTS 9/16-18 SAE #6 REF "A" "B" 4.26 CC/REV IN 3 / REV SCHEMATIC 103 BAR 1500 PSI "B" 22 SEE NOTE #2 WHITE WIRE (ATTACH TO SOLENOID START POST) CONNECT THRU "B" COIL STRAIN RELIEF 23 WIRE TO UNIT WHITE WIRE,CONNECT THRU "A" COIL STRAIN RELIEF M "A" COIL (GREEN WIRE) "B" COIL (RED WIRE) WIRE TO UNIT REV: C RED WIRE (ATTACH TO "B" COIL) GREEN WIRE (ATTACH TO "A" COIL) WHITE WIRE (ATTACH TO WHITE WIRE FROM MOTOR START SOLENOID) ITEM NO QTY PART NO DESCRIPTION BASE ASSY,M3598,MOD,STD MTR/MT P ASSY,QM,MDLR,DC,BRG RSV,1/2" SCREW,SHC,1/4-20 X 3.25,BLK OX NIPPLE,1/2 NPT X 2,SCH FITTING,ELBOW,90 DEG,PIPE,BLCK FILTER,SUCTION,1/2" NIPPLE,1/4 X ELBOW,90 DEG 1/4NPT X 1/4 NPT TUBE,RTN,STR,1/4 NPT,PVC O-RING,0.63 X 0.75 X MANIFOLD,D03,1 STA,VLV,M SCREW,SHC,1/4-20 X 1.50,BLK OX Y VALVE,ELEC,12VDC,4W/3P,D03,CC PLUG,SAE O-RING,9/16-18,HEX,SO S MOTOR,DC,12V,4.5",1 TERM SWITCH,SOL,12VDC,3-POST,M-SER STRAP,MOTOR-SOLENOID CONNECT SCREW,PAN HD,TORX,10-32 X 5/ RESV,PLASTIC,5.5X6.5X CLAMP,HOSE,WORM GEAR,RSV,M-SER PLUG,RESEV,BREATHER-FILLER CONTROL STATION,WP,SPECIAL,80" CORD ASSY,HRNSS,WHT WIRE,15"LG CORD ASSY,HRNSS,3 WIRE,24"LG FITTING,STRN.REL.WP 3/8" CORD STRAP,CONNECT PLATE,D03 VLV TERMINAL,CLS END CONNECT,SMALL SHIP LOOSE (PLASTIC PLUG) 19 "A" OUTLET PORT 9/16-18 SAE #6 (STEEL PLUG REF) "B" OUTLET PORT 9/16-18 SAE #6 (STEEL PLUG REF) "B" OUTLET PORT 9/16-18 SAE #6 (STEEL PLUG REF) C1 C1 "A" OUTLET PORT 9/16-18 SAE #6 (STEEL PLUG REF) SEE NOTE # /8" /4" 2 MOUNTING HOLES 3/8-16 UNC-2B 19 3/4" EXISTING STRAP REF DRAIN HOLE REF /16" WHITE WIRE (FROM CORD ) TERMINAL REF 1 BASE /8" 3 6 VIEW SHOWN WITHOUT RESERVOIR C REV (1)ADDED STEEL PLUGS (2X) (2) (4X) WAS (2X) (3) WAS RELIEF VALVE (01316-FILTER REF RETAINING SPRING REF) DESCRIPTION NOTES: 2. SHIP LOOSE CONTROL STATION IN A SEPARATE CARTON. (DO NOT PUT IN PUMP UNIT CARTON). 1. CLAMP MUST BE INSTALLED AT THIS LOCATION. WHITE WIRE (FROM CORD- STRAP ) REF GREEN WIRE (FROM CORD ) RED WIRE (FROM CORD ) WIRING DIAGRAM OF Y THIS PRINT IS THE PROPERTY OF MONARCH HYDRAULICS INC., AND IS NOT TO BE USED DIRECTLY OR INDIRECTLY IN ANY WAY DETRIMENTAL TO OUR INTEREST NON-SPECIFIED TOLERANCES:.XX ±.010.XXX ±.005 FRACT. ± 1/32 ANGLES ± 1/2 BREAK EDGES REMOVE BURRS [MILLIMETER] INCH DESCRIPTION: PUMP UNIT, M , HORZ MT, 12 VDC SIZE: D REV BY: LYXZ REV DATE: CUSTOMER: DEMOUNTABLE CONCEPTS 10/30/2007 MONARCH HYDRAULICS INC. DATE: DRAWN BY: EWR: GRAND RAPIDS, MI USA 8/30/2005 PMK DO NOT DRAWING #: REV: SCALE SHEET 1 OF: 1 M C 30

31 SECTION 13 Can vs. Powerseal Can vs. Powerseal REV: /32" /16" "CAN" SOLENOID POWERSEAL SOLENOID DO NOT SCALE THIS PRINT IS THE PROPERTY OF BUCHER HYDRAULICS INC., AND IS NOT TO BE USED DIRECTLY OR INDIRECTLY IN ANY WAY DETRIMENTAL TO OUR INTEREST REV NON-SPECIFIED TOLERANCES:.XX ±.010.XXX ±.005 FRACT. ± 1/32 ANGLES ± 1/2 BREAK EDGES REMOVE BURRS [MILLIMETER] INCH DESCRIPTION: CUSTOMER: GRAND RAPIDS, MI USA DESCRIPTION DATE: DRAWING #: SIZE: REV: DRAWN BY: EWR: ERROR!:DRAWNBY Can vs. Powerseal B REV BY: REV DATE: SHEET 1 OF: 1 31

32 SECTION 14 Hook Measurement Drawing 32

33 SECTION 15 Parts List Part Number DC-M3515 DC DC DC DC Y DC DC DC-F25S DC-518 DC-514 DC S DC-K13031 DCI-DL-2623 DCI-DL-2624 DC DC DC-001 DC-DL-236A DC-DL-235 DC-234 DC-POL Description Hydraulic System Power Pack Complete Hydraulic System 12V Pump Motor (Motor Only) Solenoid Switch 12VDC Solenoid Switch 12VDC Powerseal 12V D03 Solenoid Valve Pump Plastic Reservoir Pressure Relief Cartridge Valve Flow Control Valve Cylinder - 5" BORE x 18" Stroke Cylinder - 5" BORE x 14" Stroke Cylinder Packing Kit 18" cylinder Cylinder Packing Kit 14" cylinder Large Pin - Cylinder 1-1/4" x 7-3/8" Cylinder clevis pin Small Pin - Cylinder 1-1/4" x 4-3/8" Cylinder clevis pin Push Button Controller 80" Cord w/eyelets Push Button Controller 192" Cord w/eyelets Controller Box with Door and Latch Safety Lockout Key with Cable Safety Lockout Handle with Grip and Hardware Locking System Assy Spring Safety Alarm Buzzer Switch 33

34 SECTION 15 Parts List Part Number DC KIT DC-306 DC-1253 DC-1232 DC DC DCI-DL DCI-DL DC-100R200PCLZ DC-L4133 DC-L4133UO DC-L4133LO Description Push Button Controller Retrofit Kit (Replaces LVC) Back-up Alarm Light Plug, 4-Way Light Plug Receptacle, 4-Way Light Plug, 7-Way Light Plug Receptacle, 7-Way Linkage Rod (for 96" Locking Bar) Linkage Rod (for 132" Locking Bar) Linkage Rod Pin (1" x 2" Clevis Pin) Hydraulic System Complete Leg Assembly Hydraulic System Leg Assy - Upper Only Hydraulic System Lower Leg Assembly DC-100S Small Leg Pin (1" x 3-1/2") DC-106S Large Leg Pin (1" x 6") DC-103S Leg Pin Chain (18") DC N Quick Link (1/4") DC-BF Scrubber Plates (6.3125" x 7.5") DC-DL-262 DC-B-2003 Chassis Mounted Side Guides Lift Gate Remote Control - Gravity Down - Anthony Style All parts available to purchase at 34

35 Notes 35

36 SECTION 16 Contact Information for Service and Parts For Service and Parts: Phone: Fax: Web: demount.com Demountable Concepts, Inc. 200 Acorn Road Glassboro, NJ USA To preview, or order parts online visit dcixpress.com Click on the Demountable Parts link. 36